2006 FORD TRANSIT engine

Pin 27 on connector C2 for 75W ‘Theater Lighting’
DescriptionItem
Rear Theater LightingPin
27
4. Push home the cream secondary lock
Third button on key fob
For Information only
As per Additional ‘Theater’ Lighting, but the pre-crimped wire is inserted in cavity C2-12.
Terminal part number: 97BG-14474-ACB
Wire size and Color: 1.5 CSA, yellow-violet
Engine Run Signal (D+ Alternative)
To install the T-piece jumper loom the outer mirror
needs to be removed (remove the cover and 3
x M6 screws – Note, for RHD vehicles these are
shear bolts that need to be replaced, part number
W712939-S422). Push out the visible plastic insert
from inside and disconnect connector. Put in the
T-piece jumper loom and reassemble all parts,
replacing the M6 screws as required.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
172E8471227

Male and Female connectors with pin
for engine run signal shown
DescriptionItem
Male connector Pin16 - Engine Run
Signal
A
Female connector Pin16 - Engine Run
Signal
B
Additional Position Lights at the rear
For Information only
Mating connector part number: 89FG-14A624-AB* Seal: 89FG-10C930-AA (Note: this is a waterproof
connector)
Terminal part number: 93FG-14421-BBA (0.5–1.0 CSA)
Wire size and Color: 0.75 CSA, violet-white (feed); black-yellow (ground)
If larger cross section wire is to be used (1.5–2.5 CSA), the following parts should be used: Terminal
part number: 93FG-14421-BCA Seal: 89FG-10C930-BA
Connector for licence plate lighting
DescriptionItem
Feed1
Ground2
Side (and End Outline) Marker Lights
For Information only
Mating connector part number: F75B-14A624-F* Seal: integrated in connector
Terminal part number: E7EB-14461-BA
Wire size and Color: 0.75 CSA, violet-white (feed); black-yellow (ground)
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
173E8472116AB 1E847272

Sub-frame Mounted on Floor - Compliant Mount
DescriptionItem
Sub-frame Longitudinal1
Sub-frame Outriggers2
Floor of Van3
Load Compartment Tie Down (Load Lashing Point)4
Captive Compliant Bush5
For Van, Bus and Kombi:
•It is recommended to fix every mount with M8
bolt grade 8.8 minimum. For load
compartment tie down locations.
Refer to: 5.2 (page 200).
(Figures E74505 - E74508)
•It is recommended to fix sub-frame to the floor
at the load compartment tie downs only. Any
other floor contact should be padded to
prevent local stress and to allow function of
compliant mounts.
•It is not recommended to engineer through
the floor fixings to clamp around side
members.
•If the load compartment tie downs are not
suitable see, Frame Drilling and Tube
Reinforcing.
Refer to: 5.11 Frame and Body Mounting (page
222).
•Very stiff sub-frames should not be rigidly
mounted to the floor, please refer to Figure
E75876 for an example of a compliant mount.
Compliant bushes should allow up to +/-12mm
movement at a rate of 100kg per 1.0mm
deflection with only the rear pair of load
compartment tie down mounting brackets
being fixed.
•Support legs, if required, must be fitted directly
to the sub-frame
•Support legs must be designed to prevent any
adverse strain on the vehicle structure when
operating the equipment
CAUTIONS:
Safety devices must ensure the legs
are deployed when operating the
lifting equipment.
Safety devices must ensure the legs
are stowed and locked away prior
to engaging vehicle drive.
For Chassis Cab:
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
190E7587642351

For Chassis Cab with tail lift design as described
above it is recommended to use unique body
sub-frame for fixing to Chassis Cab structure. For
connection between sub-frame Chassis Cab
body structure please refer to Figure E74696.
For Chassis Cab with under-slung tail lift load
capacity is up to 1000kg at 1000mm from rear
end of chassis frame to center of load if mounted
and functioning on centre line of vehicle. If
mounted and functioning off center line or at the
side of the vehicle load capacity is reduced to
500kg at 1000mm from side/rear end to center
of load.
Greater off-sets and/or loads require additional
stabilizing equipment such as outriggers or
ground jacks. It is recommended not to increase
vehicle body stress over limit as given by load
factors above. If uncertain please consult your
local national sales representative or the Vehicle
Converter Advisory Service [email protected].
It is the Vehicle converters responsibility to fit a
decal to the converted vehicle stating that the
equipment must not be used without
outriggers/ground jacks in operating position. It
is also the vehicle converters responsibility to
guarantee safe functioning of the equipment.
For hydraulic tail lifts as used for general loading
or more specialized for wheel-chair lifts please
refer to Figure E75874.
5.1.7 Partitions (Bulkhead) - Driver
and Front Passenger(s)
Protection on Van, Bus and Kombi
The following two figures show the standard
bulkhead fixing locations on B-pillar. These are
hexagonal holes for M6 thin sheet rivet type nuts.
The standard range of Ford Regular Production
Option bulkheads can be retro-fitted at these
points.
Conversely a Ford Regular Production Option
bulkheads can also be removed.
Ford Regular Production Option bulkheads do
have a clearance between bulkhead and body
structure to allow natural body flexing and an air
circulation from the cab to the rear load space
for ventilation control.
Air circulation and body flexing must be also given
consideration when engineering an alternative
bulkhead. It is not recommended to restrict
driver’s or passengers’s seat adjustment travel.
It is the vehicle converter’s responsibility to ensure
local current legislation, governing bulkheads and
protective window grilles, is met. It is also the
converter’s responsibility to ensure legal load
constraint requirements if using a non Ford
Regular Production Option bulkhead.
Low Roof Bulkhead Fixing Holes
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
192E75919

Glass Racking on Outside of Van

Glass Racking on Outside of Van - Through Fixed to Internal Racking (Recommended Minimum )
DescriptionItem
Top Load Bearing Attachments (2x)1
Lower Load Bearing Attachments Through Body side to Internal Racking (2x)2
New Through Bolts (2 bolts per top attachment and 1 bolt per lower attachment)2
For designing glass carrying rack on body side
outer following unique requirements are
recommended:
•Do not fix the rack to the drip rail
•Construct internal rack and bolt through the
body side to the internal rack, see figure
E75923 below
•Location in the drip rail gutter, if used, must be
protected to prevent future corrosion
5.1.9 Front End Integrity for
Cooling, Crash, Aerodynamics
and Lighting
Cooling
Continuous air flow through the front end and
engine compartment is not to be hindered by
adding any additional equipment. If uncertain
please consult the Vehicle Converter Advisory
Service [email protected].
Crash
Do not cut, drill or weld any parts that are load
path relevant in case of crash. Do not add material
in the crash zone. This could affect the crash
sensor calibration.
The side airbag system is not permitted if:
•A swiveling device is fitted on the front seats.
•A side wall or any other additional material or
structure is attached to the B-pillar inner and/or
outer area.
Lighting:
Do not alter the lighting system.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
198E759233123

Static & Dynamic Sealing and
Finishing
Use Ford approved sealing and finishing material,
and underbody corrosion protection.
Refer to: 5.10 Corrosion Prevention (page 221).
Ensure proper sealing against ingress of water,
salt, dust etc. after cutting or drilling the body.
5.1.10 Tipper Bodies
For tipper conversions single an double Chassis
Cab versions except extended rear chassis
frame can be used. All variants allow single and
three way tipping.
It is recommended to have the tipping system
operative only when the engine is running. It is
also recommended to have the master control
switch in the security of the cab. According
routing of wires and hydraulic lines please refer
to section hydraulic lift.
Ensure that axle plated weights including the
front axle minimum are not exceeded.
For tipper sub-frames please refer to the
following guidelines:
•Design for full length continuous frame with
mountings for motor, pump unit, reservoir,
pivot points and ram
•Use all mounting points on chassis frame to
mount sub-frame
•The rear two sets of chassis frame mounting
brackets should have a full torque with 100%
grip. The attachment to the remaining forward
chassis frame brackets must be precisely
located and retained, but allow some relative
flexing between the sub-frame and chassis
frame. That is clamp control devices such as
conical washer stacks or machine springs with
self locking fastenings.
•Very stiff sub-frames may damage the chassis
frame by preventing its natural flexing,
therefore compliant mounts should be captive
fail safe with up to plus and minus 12mm
compliance, vehicle laden or un-laden
whichever is worst case, rated 2mm
deflection minimum per 200kg mass at each
chassis frame forward mount, please see also
Figures E74696 Sub-frame attachment to
Chassis frame and Figure E75880 Rigid or
Torsion Stiff sub-frame for Chassis Cab.
•Use two M10 grade 8.8 minimum bolts,
washers and self locking nuts at each solid
and compliant chassis frame location.
•Sub-frame must extend to the back of the
cab and attach to all mounting locations, with
the forward end designed to minimize local
frame stress, please refer to Figure E74575
Sub-frame for low floor or other equipment.
However it is preferable to mount the
sub-frame onto the mounting brackets with
a clearance to the chassis frame top surface.
•Side tipping loads/forces must be resolved
by the sub-frame. It is not recommended to
strain the chassis frame.
5.1.11 Tank and Dry Bulk Carriers
Due to the high rigidity of tanks it is necessary to
isolate the tank and its sub-frame from the
chassis frame allowing the chassis frame to
naturally flex. Please refer to the following
guidelines:
•Mount tank to full length of sub-frame.
•Mount sub-frame to all chassis frame
mounting points.
•The rear two sets of chassis frame mounting
brackets should have solid full bolts torque
with 100% grip.
•The remaining forward location mounts must
be compliant to allow relative chassis frame
to sub-frame deflections.
•Sub-frame must extend to the back of the
cab and not contact chassis frame at forward
end under worst case deflection.
•Compliant mounts should have captive fail
safe through bolts, please refer to Figures
E74696 Sub-frame attachment to Chassis
frame and Figure E75880 Rigid or Torsion Stiff
sub-frame for Chassis Cab, with up to
plus/minus 12mm compliance, vehicle laden
or un-laden whatever is worst case, rated at
2.0mm minimum deflection per 200kg mass
each.
•Use two M10 grade 8.8 minimum bolts,
washers and self lock nuts per chassis frame
mount bracket at each solid and compliant
location.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
199

Section through typical Van Body Side for Window Engineering
DescriptionItem
Horizontal Section Through 'C'-PillarA
Horizontal Section Through Rear Vent Window Hinge PillarB
Vertical Section Through Side Window (Non Side Load Door)C
Section through typical Van Body Side for Window Engineering
Window trim strip4Glass1
Use standard vent hinge assembly5Adhesive2
Cut within 0 and 1.5mm of inner body panel flange edge all around3
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
2121413ABC21251424444211E74533

5.7 Roof Opening Panel
5.7.1 Driver's Standing Head
Room
When planning cab walk-through capability on a
Van, Bus or Kombi, select the Special Vehicle
option, which replaces the front headlining and
parcel shelf in Vans and provides the maximum
height headlining for increased standing head
room height.
For Chassis Cab and Cab Van Floor vehicles, the
Special Vehicle Option “Roof Cutout Preparation”
can be ordered as shown in below Figure
E74678. Please consult your local National Sales
Company representative for availability.

Chassis Cab with Roof Cut Out Preparation
5.7.2 Back Panel Removal
When planning, select the Special Vehicle Option,
which has a detachable cab back panel (Chassis
Cab). Please consult your local National Sales
Company representative for availability.
5.7.3 Cab Roof Removal
For enhanced head room in the cabin of a Single
Chassis Cab, it is recommended to specify the
base vehicle with the Special Vehicle Option Roof
Cutout Preparation Pack, which provides a
perforated roof cut-out (only on Chassis Cabs)
and deletes “B”-pillar roof bow. Alternative
structure is added to comply with seat belt pull
requirements.
A unique Body Builder application where the
original Ford roof and back panel structure are
cut away must have a bolt-on reinforcing 'goal
post' structure or equivalent to resist seat belt
pull loads.
Body Preparation
When it is not possible to specify the Special
Vehicle Option it is advisable to observe the
engineering intent of the Special Vehicle
Engineering design.
Where new add-on bodies are attached to the
cab for an enclosed walk-through, the body
structure must be self-supporting and fixed such
that no local stress is created in the parent cab
structure.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
214E74678